Endoscopic stapler

ABSTRACT

A surgical stapler is described herein which includes a shaft portion and a tool assembly supported on a distal end of the shaft portion. The tool assembly includes an anvil and a cartridge body which rotatably supports a plurality of staples within notches. At least one firing cam is provided to sequentially to engage and rotate each of the staples to fire the staples from the cartridge body. Each of the staples includes first and second legs axially offset from each other and interconnected by an intermediate portion. At least one firing cam is provided to sequentially to engage and rotate each of the staples to fire the staples from the cartridge body. The at least one firing cam includes axially offset cam members.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/994,228, filed Jan. 13, 2016, now U.S. Pat. No. 10,463,368, whichclaims the benefit of and priority to U.S. Provisional PatentApplication No. 62/145,857 filed Apr. 10, 2015, the entire disclosureseach of which are incorporated by reference herein.

BACKGROUND Technical Field

The present disclosure relates to surgical staplers, and moreparticularly, to surgical staplers for endoscopic use. The presentdisclosure also relates to surgical staples for use with endoscopicsurgical staplers.

Background

Surgical staplers typically include a cartridge housing a plurality ofstaples, an anvil for forming the staples as the staples are ejectedfrom the cartridge, and a knife to effect simultaneous dissection andsuturing of tissue. When compared to applying manually threaded sutures,the use of surgical staplers to suture and dissect tissue has increasedthe speed of the surgical procedure and thus, minimized patient trauma.

In an endoscopic surgical procedure, a surgical stapler is insertedthrough a small incision in the skin or through a cannula to access asurgical site. Due to the complexity of known surgical staplers as wellas the staple size requirements of known staple forming apparatus, acontinued need exists for small diameter surgical staplers suitable forendoscopic use.

SUMMARY

The present disclosure is directed to a surgical stapler having a toolassembly including an anvil and a staple cartridge having a series ofstaples which are supported and configured to be rotatably ejected fromthe staple cartridge into the anvil to suture tissue. The manner inwhich the staples are supported and ejected from within the staplecartridge facilitates the use of a small diameter tool assembly thatincludes staples capable of suturing thicker tissues than would normallybe associated with tool assemblies with such a small diameter. Inembodiments, the surgical stapler includes at least one firing camhaving staggered cam members and the staples are configured withstaggered legs. Each of the staple legs has a D-shaped configurationwhen deformed.

In one aspect of the disclosure, a surgical stapler includes a shaftportion and a tool assembly supported on a distal end of the shaftportion. The tool assembly includes an anvil and a cartridge assemblyhaving a cartridge body including at least one leg defining a pluralityof notches and a plurality of staples. Each of the staples has anintermediate portion interconnecting first and second staple legs. Theintermediate portion of each of the staples has a first end connected tothe first leg and a second end connected to the second leg, wherein thefirst and second ends of the intermediate portion are axially offsetfrom each other. The surgical stapler includes at least one firing camhaving a distal end defining a cam member including first and second camsurfaces. The first and second cam surfaces are axially offset from eachother. The cam member is movable within the tool assembly to move thefirst and second cam surfaces into sequential engagement with the firstand second staple legs, respectively, of each of the plurality ofstaples, wherein engagement between the cam member and the first andsecond staple legs of each of the plurality of staples effectsrotational movement of each of the plurality of staples to fire each ofthe plurality of staples from the cartridge body.

In embodiments, each notch of the plurality of notches is configured torotatably support one of the staples of the plurality of staples.

In some embodiments, the at least one leg of the cartridge body definesa plurality of cutouts. Each of the plurality of cutouts is spaced fromadjacent notches of the plurality of notches and is configured toreceive a first portion of the intermediate portion of one of thestaples of the plurality of staples.

In embodiments, the intermediate portion of each of the staples isS-shaped and includes a distal U-shaped portion that is configured to bereceived in a respective one of the cutouts of the plurality of cutoutson the at least one leg of the cartridge body.

In certain embodiments, each of the notches of the plurality of notchesis configured to rotatably receive a proximal portion of theintermediate portion of a respective one of the staples of the pluralityof staples.

In embodiments, the first and second staple legs of each of the staplesof the plurality of staples has a curved configuration and each of thefirst and second staple legs defines a D-shape when formed against theanvil.

In some embodiments, each notch of the plurality of notches includes acylindrical slot that is configured to receive the proximal portion ofthe intermediate portion of a respective one of the staples of theplurality of staples in a snap-fit manner.

In certain embodiments, the at least one leg of the cartridge bodyincludes two spaced legs and the plurality of notches is spaced axiallyalong each of the two spaced legs, wherein each of the plurality ofnotches rotatably supports one of the staples of the plurality ofstaples.

In embodiments, the surgical stapler includes first and second cartridgechannels. Each of the first and second cartridge channels has a distalend defining a U-shaped member and each of the two spaced legs of thecartridge body is secured within a respective one of the U-shapedmembers.

In some embodiments, the at least one firing cam includes first andsecond firing cams. Each of the cam members of the first and secondfiring cams has a U-shape and is positioned about one of the two spacedlegs of the cartridge body and within the U-shaped member of one of thefirst and second cartridge channels.

In certain embodiments, the surgical stapler includes a pivot memberpivotably secured to the distal end of the shaft portion and fixedlysecured to each of the first and second cartridge channels.

In embodiments, the surgical stapler includes a first articulation linkhaving a distal end secured to a proximal end of the first cartridgechannel and a second articulation link having a distal end secured to aproximal end of the second cartridge channel. The first and secondarticulation links are axially movable to effect axial movement of thefirst and second cartridge channels in relation to each other to pivotthe pivot member in relation to the shaft portion.

In some embodiments, a pivotable articulation member interconnects thefirst articulation link to the second articulation link such thatmovement of the first articulation link in one direction effectsmovement of the second articulation link in an opposite direction.

In certain embodiments, each of the first and second staple legs of eachof the plurality of staples has a tapered tip.

In embodiments, the at least one leg of the cartridge body includes aplurality of dimples and each of the plurality of dimples is positionedto engage one of the first and second legs of one of the staples of theplurality of staples to stabilize the staple on the cartridge body.

In another aspect of the disclosure, a surgical staple is described thatincludes a first curved leg, a second curved leg, and an intermediateportion interconnecting the first curved leg to the second curved leg.The intermediate portion of the staple has a first end connected to thefirst curved leg and a second end connected to the second curved leg,wherein the first and second ends of the intermediate portion areaxially offset from each other.

In some embodiments, the intermediate portion of the staple is S-shapedand includes a distal U-shaped portion and a proximal portion.

In certain embodiments, each of the first and second legs includes atapered tip.

In embodiments, the first and second legs of the staple is configured tohave a D-shape when formed against an anvil.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments of the presently disclosed small diameter surgicalstapler are described herein with reference to the drawings, wherein:

FIG. 1 is a side perspective view of one embodiment of the presentlydisclosed small diameter surgical stapler in an unapproximated position;

FIG. 1A is a side perspective view from the distal end of a staplerreload of the surgical stapler shown in FIG. 1;

FIG. 2 is a side perspective view from the proximal end of the surgicalstapler reload shown in FIG. 1A;

FIG. 3 is a side perspective, exploded view of the surgical staplerreload shown in FIG. 1A;

FIG. 3A is a top, perspective, exploded view of a distal end of theupper housing half-section of a proximal body portion, a pivot member,and a connecting member of the surgical stapler reload shown in 3;

FIG. 3B is an enlarged view of the indicated area of detail shown inFIG. 3;

FIG. 3C is an enlarged view of the indicated area of detail shown inFIG. 3;

FIG. 4 is an enlarged view of the indicated area of detail shown in FIG.1;

FIG. 5A is a perspective view from one side of a staple of the staplerreload shown in FIG. 3;

FIG. 5B is a top view of the staple shown in FIG. 5A;

FIG. 5C is a perspective view from the other side of the staple shown inFIG. 3;

FIG. 6 is an enlarged view of the indicated area of detail shown in FIG.3C;

FIG. 7 is an enlarged view of the indicated area of detail shown in FIG.6;

FIG. 7A is a top view of the cartridge assembly of the surgical staplerreload shown in FIG. 1A;

FIG. 7B is an enlarged view of the indicated area of detail shown inFIG. 7A;

FIG. 8 is a side, cutaway view of the cartridge body supporting astaple;

FIG. 9 is a side, perspective view of a cartridge channel of the staplerreload shown in FIG. 3;

FIG. 10 is a top view of the cartridge channel shown in FIG. 9;

FIG. 11 is an enlarged view of the indicated area shown in FIG. 10;

FIG. 12 is an enlarged view of the indicated area of detail shown inFIG. 9;

FIG. 13 is a perspective, cross-sectional view taken along section line13-13 of FIG. 12.

FIG. 14 is a side, perspective view of a staggered firing cam of thestapler reload shown in FIG. 3;

FIG. 15A is an enlarged view of the indicated area of detail shown inFIG. 14;

FIG. 15B is a top view of the distal end of the staggered firing camshown in FIG. 14;

FIG. 16 is a perspective, cross-sectional view taken along section line16-16 of FIG. 15;

FIG. 17 is a side, perspective view of the cartridge assembly of thestapler reload shown in FIG. 3 supported on a distal end of the firingcams;

FIG. 18 is an enlarged view of the indicated area of detail shown inFIG. 17;

FIG. 19 is a side, perspective view of the cartridge assembly of thestapler reload shown in FIG. 3 supported on the distal ends of thecartridge channels and firing cams;

FIG. 20 is an enlarged view of the indicated area of detail shown inFIG. 19;

FIG. 21 is a top view of the stapler reload shown in FIG. 1A with thetool assembly in an unapproximated position;

FIG. 22A is a cross-sectional view taken along section line 22A-22A ofFIG. 21;

FIG. 22B is a cross-sectional view taken along section line 22B-22B ofFIG. 21;

FIG. 23A is a cross-sectional view taken along section line 23A-23A ofFIG. 21;

FIG. 23B is a cross-sectional view taken along section line 23B-23B ofFIG. 21;

FIG. 24A is an enlarged view of the indicated area of detail shown inFIG. 22A;

FIG. 24B is an enlarged view of the indicated area of detail shown inFIG. 22B;

FIG. 25A is a cross-sectional view taken along section line 25A-25A ofFIG. 21;

FIG. 25B is a cross-sectional view taken along section line 25B-25B ofFIG. 21;

FIG. 26 is a top, perspective view of the tool assembly of the staplerreload shown in FIG. 21 with the tool assembly in the approximatedposition and the firing cams advanced into engagement with aproximal-most staple of the plurality of staples;

FIG. 27 is a side, cross-sectional view of the tool assembly of thestapler reload shown in FIG. 26;

FIG. 28 is an enlarged view of the indicated area of detail shown inFIG. 27;

FIG. 29 is a view of the area of detail shown in FIG. 28 with the firingcams advanced into engagement with a second proximal-most staple;

FIG. 30 is a view of the area of detail shown in FIG. 29 with the firingcams advanced into engagement with a third proximal-most staple;

FIG. 30A is a view of the area of detail shown in FIG. 30 with thefiring cam advanced into engagement with the fourth proximal-most stapleand the proximal-most staple disengaged from the cartridge body;

FIG. 31 is a perspective view of a staple of the tool assembly of thestapler reload shown in FIG. 26 after the staple has been deformed;

FIG. 32 is a cross-sectional view taken along section line 32-32 of FIG.26;

FIG. 33 is a side, perspective view of the stapler reload shown in FIG.1A in a non-articulated and unapproximated position with the proximaltube of the proximal body portion and the shaft tube of the shaftportion removed;

FIG. 34 is a top perspective view of the proximal body portion of thestapler reload with the proximal tube removed and the upper housing halfsection removed;

FIG. 35 is a top perspective view of the upper housing half section ofthe proximal body portion of the stapler reload;

FIG. 36 is a top, perspective view of the proximal body portion of thestapler reload shown in FIG. 35 with the proximal tube and the upperhousing half section removed and the articulation member rotated; and

FIG. 37 is a top view of the tool assembly of the stapler reload, shownin FIG. 26 in an articulated position.

DETAILED DESCRIPTION OF EMBODIMENTS

Embodiments of the presently disclosed endoscopic surgical staplerincluding staples with staggered legs will now be described in detailwith reference to the drawings wherein like reference numerals designateidentical or corresponding elements in each of the several views. Inthis description, the term “proximal” is used generally to refer to theportion of the apparatus that is closer to a clinician, while the term“distal” is used generally to refer to the portion of the apparatus thatis farther from the clinician. In addition, the term “endoscopic”procedure is used generally to refer to endoscopic, laparoscopic,arthroscopic, and any other surgical procedure performed through a smallincision or a cannula inserted into a patient's body. Finally, the termclinician is used generally to refer to medical personnel includingdoctors, nurses, and support personnel.

The presently disclosed surgical stapler includes a tool assembly whichsupports a series of staples which are supported and configured to berotatably ejected from a staple cartridge into an anvil to suturetissue. The manner in which the staples are supported and ejected fromwithin the staple cartridge facilitates the use of a small diameter toolassembly which includes staples capable of suturing thicker tissues thanwould normally be associated with tool assemblies with such a smalldiameter. In embodiments, the surgical stapler includes at least onefiring cam having staggered cam members and the staples are configuredwith staggered legs. Each of the staple legs has a D-shapedconfiguration when deformed.

FIG. 1-2 illustrate the presently disclosed surgical stapler 10 whichincludes an actuating device 12 having a handle assembly 12 a, a bodyportion 14 which extends distally from the handle portion 12, and astapler reload 100 supported on a distal end of the body portion 14. Thedistal end of the body portion 14 is adapted to releasably engage aproximal end of the reload 100 such that actuation of the actuatingdevice 12 effects operation of the reload 100. A suitable actuatingdevice is disclosed in detail in U.S. Pat. No. 5,865,361 (“361 patent”)and U.S. Pat. No. 7,143,924 (“924 patent”) which are incorporated hereinin their entirety by reference. Although the presently disclosedactuating device is illustrated as a manually actuated handle assembly,it is envisioned that other known actuating devices including roboticdevices, motorized devices, and/or electrically or mechanically drivendevices can be used to actuate the reload 100.

In an alternate embodiment, the reload 100 can be fixedly attached tothe distal end of the handle assembly 12 and only a cartridge assemblyof a tool assembly can be removable and replaceable. Alternatively, aremovable and replaceable reload can also have a removable andreplaceable cartridge.

Referring also to FIGS. 3-3C, the reload 100 includes a proximal bodyportion 110, an elongated shaft portion 112 and a tool assembly 114. Theproximal body portion 110 includes an inner housing 116 (FIG. 25A)defined by an upper housing half-section 116 a and a lower housinghalf-section 116 b. The housing half-sections 116 a and 116 b definechannels which slidably receive a proximal drive member 118, a firstarticulation link 120 and a second articulation link 122. The housinghalf-sections 116 a and 116 b are received within a proximal body tube125.

The first articulation link 120 is connected to the second articulationlink 122 by an articulation member 123 which will be described in detailbelow. The proximal drive member 118 supports a drive coupler 124 thatis adapted to engage a control rod (not shown) of the actuating device12 (FIG. 1) to operate the tool assembly 114 of the reload 100. Theproximal drive member 118 also supports a locking assembly 126 whichincludes a locking device 128 and a spring 130. Operation of the drivecoupler 124 and the locking assembly 126 are described in the '361patent which is incorporated herein by reference. As such, the drivecoupler 124 and locking assembly 126 will not be described in furtherdetail herein. A distal end of the proximal drive member 118 includes aa T-shaped recess 118 a. In addition, the distal ends of the firstarticulation link 120 and the second articulation link 122 include hookportions 120 a and 122 a, respectively (FIG. 3B). Each of these hookportions 120 a and 122 a and the T-shaped recess 118 a are described infurther detail below.

The elongated shaft portion 112 of the reload 100 includes an innerhousing 134 (FIG. 25A) defined by upper and lower housing half-sections134 a and 134 b which are received within a shaft portion tube 112 a. Aproximal end of the inner housing 134 of the elongated shaft portion 112is received within the distal end of the inner housing 116 of theproximal body portion 110 and includes an annular recess 135. Theannular recess 135 receives a protrusion 116 c (FIG. 25A) formed withinthe inner housing 116 to axially secure the inner housing 116 of theproximal body portion 110 to the inner housing 134 of the shaft portion112. The upper and lower housing half-sections 134 a, 134 b of theelongated shaft portion 112 define internal channels (not shown) whichslidably receive a pair of distal drive members 136 a, 136 b, a pair offiring cams 138 a, 138 b, and a pair of cartridge channel members 140 a,140 b. A proximal end of each of the cartridge channels 140 a, 140 bdefines a cutout 142 a, 142 b, respectively. The cutouts 142 a, 142 b ofthe cartridge channels 140 a, 140 b receive one side of the hookportions 120 a, 122 a (FIG. 3B), respectively, of the first and secondarticulation links 120, 122 such that linear movement of the first andsecond articulation links 120, 122 effects linear movement of thecartridge channels 140 a,140 b as described in further detail below.

A proximal end of each of the distal drive members 136 a, 136 b includesa hook portion 144 a and defines a recess 144 b. Similarly, the proximalend of the firing cams 138 a, 138 b includes a hook portion 146 a anddefine a recess 146 b. Each of the recesses 144 b, 146 b is defined by adistal wall 144 c, 146 c, respectively. The distal wall 146 c definingeach recess 146 b of the firing cams 138 a, 138 b is positioned distallyof the distal wall 144 c defining each recess 144 b of the distal drivemembers 136 a, 136 b. The proximal drive member 118 and the proximal endof the distal drive members 136 a, 136 b are connected by a drive memberlink 119. The drive member link 119 has a proximal end configured to bereceived in the T-shaped slot 118 a of the proximal drive member 118. Adistal end of the drive member link 119 includes a hook portion 119 aand defines a recess 119 b. The hook portion 119 a is received withinthe recesses 144 b, 146 b of the distal drive members 136 a, 136 b andthe firing cam 138 a, 138 b, respectively, such that the hook portions144 a, 146 a of the distal drive members 136 a, 136 b and the firingcams 138 a, 138 b, respectively, are slidably received within the recess119 b of the drive member link 119. As such, movement of the proximaldrive member 118 effects corresponding movement of the drive member link119. As the drive member link 119 is moved distally, the hook portion119 a of the drive member link 119 moves within the recesses 144 b and146 b of the distal drive members 136 a, 136 b and the firing cams 138a, 138 b, respectively. When the hook member 119 a engages the distalwalls 144 c, 146 c defining the recesses 144 b and 146 b of the distaldrive members 136 a, 136 b and the firing cams 138 a, 138 b,respectively, distal movement of the drive member link 119 will effectcorresponding distal movement of the distal drive members 136 a, 136 band the firing cams 138 a, 138 b, respectively. As discussed above, thedistal wall 146 c of the recesses 146 c of the firing cams 138 a, 138 bare positioned distally of the distal walls 144 c of the distal drivemembers 136 a, 136 b. As such, distal movement of the drive member link119 will effect distal movement of the distal drive members 136 a, 136 bprior to effecting distal movement of the firing cams 138 a, 138 b asdescribed in further detail below. It is envisioned that the proximaldrive member 118 and the drive member link 119 can be formed as aunitary component. As best shown in FIG. 3C, the distal end of thedistal drive members 136 a and 136 b are secured to a working member 150such as by welding. Alternately, other securement techniques can be usedto secure the distal end of the drive members 136 a, 136 b to theworking member 150. In one embodiment, the working member 150 includesan upper beam 152, a lower beam 154 and a vertical strut 156interconnecting the upper and lower beams 152, 154. A cutting edge 156 ais formed on or supported on a distal end of the vertical strut 156. Thevertical strut 156 is movably positioned between the cartridge channels140 a, 140 b, the firing cams 138 a, 138 b and the legs 188 of thecartridge body 184 as described in further detail below. The workingmember 150 is positioned and configured to move through the toolassembly 114 when the distal drive members 136 a, 136 b are moveddistally within the elongated shaft portion 112 to actuate the toolassembly 114.

Referring again to FIGS. 3 and 3A, a pivot member 157 is secured to adistal end of the shaft housing half-sections 134 a, 134 b by upper andlower connecting members 160 a, 160 b. Each connecting member 160 a, 160b includes a distal end which defines an opening 162 and a proximal end164 which has a stepped configuration. The stepped configuration of theproximal end 164 of each connecting member 160 a, 160 b is receivedwithin a cutout 166 formed in the distal end of each of the upper andlower shaft housing half-sections 134 a, 134 b to axially fix the upperand lower connecting members 160 a, 160 b to the upper and lower shafthousing half-sections 134 a, 134 b, respectively. The openings 162 ofeach of the upper and lower connecting members 160 a, 160 b receive arespective pivot pin 170 (only one shown, FIG. 3A) formed on the upperand lower surfaces of the pivot member 157 to pivotally secure the pivotmember 157 to the shaft housing half-sections 134 a, 134 b. The pivotmember 157 also includes two transversely extending posts 172. Each post172 is received in an opening 210 a (FIG. 3C) formed in one of thecartridge channels 140 a, 140 b to secure the pivot member 156 betweenthe cartridge channels 140 a, 140 b.

Referring to FIGS. 3-8, the tool assembly 114 includes a cartridgeassembly 180 and an anvil 182. The cartridge assembly 180 (FIG. 6)includes a cartridge body 184 and a plurality of staples 185. Thecartridge body 184 includes a tapered distal end 186 and first andsecond spaced legs 188. The tapered distal end 186 of the cartridge body184 functions as a tissue guide and includes three proximally extendingfingers 190. One of the fingers 190 is positioned on each side of eachof the spaced legs 188 with one finger 190 being positioned between thespaced legs 188. Each of the fingers 190 defines a recess 192 with anadjacent leg 188. The recesses 192 receive the distal ends 191 (FIG. 3C)of the cartridge channels 140 a, 140 b to secure the cartridge body 184to the distal end of the cartridge channels 140 a, 140 b.

Each of the first and second spaced legs 188 of the cartridge body 184includes a series of rectangular cutouts 196 and notches 198 which arespaced along each leg 188 of the cartridge body 184. The rectangularcutouts 196 and spaced notches 198 are configured and dimensioned toreleasably engage the staples 185 as described in detail below. A base198 a of each notch 198 has a circular configuration to facilitaterotation of the staples 185 within a respective notch 198 as the staplesare formed as described in further detail below. A series of dimples 199are spaced along inner and outer walls of the legs 188 of the cartridgebody 184. The dimples 199 are positioned to engage a proximal legportion 202 a of each staple 185 to secure the staples 185 to thecartridge body 184 as described in detail below.

Referring to FIGS. 5A-5C, each of the staples 185 includes a pair ofstaple legs 200 a, 200 b interconnected by an intermediate portion 201.Each of the staple legs 200 a, 200 b has tapered tip 200 c and a curved,substantially V-shaped body 202. The intermediate portion 201 isS-shaped and has a first end connected to the staple leg 200 a and asecond end connected to the staple leg 200 b.

The V-shaped body 202 of each of the staple legs 200 a, 200 b includes aproximal leg portion 202 a and a distal leg portion 202 b. One end ofthe proximal leg portion 202 a is connected to one end of theintermediate portion 201 and the other end of the proximal leg portion202 a is connected to one end of the distal leg portion 202 b. The otherend of the distal leg portion 202 b defines a tapered tip 202 c. Thedistal leg portion 202 b is curved upwardly and rearwardly towards theintermediate portion 2013.

Referring again to FIGS. 5A-8, each rectangular cutout 196 of thecartridge body 184 is configured to receive a distal U-shaped portion204 a of the intermediate portion 201 of the staple 185 to secure thestaples 185 to a respective leg 188 of the cartridge body 184. Inaddition, each notch 198 is configured to receive a proximal portion 204b of the intermediate portion 201 of the staple 185 in snap-fitengagement to rotatably secure the staples 185 to respective legs 188 ofthe cartridge body 184. As discussed above, engagement between thedimples 199 and the proximal leg portion 202 a of each staple 185assists in releasably securing the staples to the cartridge body 184.With the staples 185 secured to the legs 188 of the cartridge body 184,the proximal portion 204 b of the intermediate portion 201 of eachstaple 185 extends transversely across a respective leg 188 of thecartridge body 184 such that the legs 200 a, 200 b of each staple 185are positioned on opposite sides of a respective leg 188 of thecartridge body 184 on which the staple 185 is supported.

As best shown in FIG. 8, the legs 200 a and 200 b of each staple 185 arestaggered along a longitudinal axis of the cartridge body 184 by thedistance defined by the width “X” (FIG. 5A) of the intermediate bodyportion 201. In one embodiment, the outer leg 200 a of each staple 185is positioned proximally of the inner leg 200 b.

Referring to FIGS. 3-3C and 9-13, each of the cartridge channels 140 aand 140 b has a substantially similar configuration. As such, onlycartridge channel 140 b will be described in detail herein. Cartridgechannel 140 b (FIG. 3) includes a resilient body that extends from theproximal body portion 110 (FIG. 1) of the reload 100 (FIG. 1) to thetool assembly 114. A distal end of each cartridge channel 140 b includesa U-shaped member 208 that receives a leg 188 of the cartridge body 184and defines two openings (FIG. 13) including a proximal opening 210 aand a distal opening 210 b. The proximal opening 210 a receives the post172 (FIG. 3A) of the pivot member 157 to secure the cartridge channel140 b of the cartridge assembly 180 to the pivot member 157. The distalopening 210 b receives a pin 211 (FIG. 3C) that extends through theopening 182 a in a proximal end of the anvil 182, through the opening210 b in the cartridge channel 140 b, and through an opening 214 (FIG.6) in the proximal end of each of legs 188 of the cartridge body 184 tosecure the proximal end of the legs 188 of cartridge body 184 to therespective cartridge channels 140 a, 140 b. A distal end 191 of eachU-shaped member 208 is received in adjacent recesses 192 (FIG. 6) formedon opposite sides of each leg 188 of the cartridge body 184. The distalend 191 is defined by a pair of cutouts 191 a (FIG. 12) and distallyextending fingers 191 b (FIG. 12). A bottom wall 193 (FIG. 13) of eachcartridge channel 140 b is w-shaped and defines channels that guide therotational movement of the staples 185 within the cartridge channel 140b as the staples 185 are ejected from the cartridge assembly 180.

Referring to FIGS. 3-3C and 14-18, the distal end 220 of each firing cam138 a and 138 b defines a cam member 222. Each cam member 222 has acurved shape. In certain embodiments, the cam member 222 includes afirst portion for moving the staple 185 into engagement with stapleforming depressions 182 b of the anvil 182 and at least one otherportion for forming the staple 185 into a closed configuration. In theembodiment shown, the cam member 222 has a portion for partially formingthe staple 185, and a portion for deforming the staple 185 into itsfinal configuration as described in further detail below.

Each cam member 222 of the first and second firing cams 138 a, 138 b hasfirst and second cam surfaces 222 a, 222 b that are staggered along thelongitudinal axis of the firing cam 138. Each cam member 222 is U-shapedand defines a channel 224 that receives a respective one of legs 188(FIG. 3C) of the cartridge body 184. The cam members 222 are slidableabout the respective legs 188 of the cartridge body 184 to move thefirst and second cam surfaces 222 a, 222 b into engagement with the legs200 a, 200 b of the staples 185 supported on the respective legs 188 ofthe cartridge body 184.

Each of the cam surfaces 222 a, 222 b is curved and defines a firstcurved surface 226 and a second curved surface 228 which areinterconnected by a plateau 230. The cam surfaces 222 a, 222 b have aheight that increases from a distal end of each of the cam surfaces 222a, 222 b towards a proximal end of each of the cam surfaces 222 a, 222b. The first curved surface 226 of the cam surfaces 222 a, 222 b isconfigured to initiate deformation of a leg 200 a, 200 b of a staple 185and the second curved surface 228 is configured to complete deformationof the leg 200 a, 200 b of a staple 185 and to disengage the leg 200 a,200 b from the circular base 198 a of a respective notch 198 of thecartridge body 184 as described in further detail below.

Referring also to FIGS. 19 and 20, when the cartridge channels 140 a and140 b are positioned about the legs 188 of the cartridge body 184 andsecured to the cartridge body 184, a space “s” (FIG. 32) is definedbetween sidewalls of the legs 188 of the cartridge body 184 and innerwalls of the cartridge channels 140 a, 140 b. The staple legs 200 a, 200b are positioned in the space “s”. In addition, the cam surfaces 222 a,222 b of each of the firing cams 138 a and 138 b are slidably supportedin the spaces “s”. When the firing cams 138 a, 138 b are advanceddistally from a retracted position to an advanced position, the camsurfaces 222 a, 222 b are moved between the legs 188 and the cartridgechannels 140 a, 140 b into sequential contact with the legs 200 a, 200 bof the staples 185 (FIG. 18) to urge the staples 185 from the cartridgebody 184 into the staple forming depressions 182 b (FIG. 22A) of theanvil 182 as described in further detail below.

Referring to FIGS. 3C and 21-25B, the anvil 182 defines an elongatedslot 252 and an elongated recess 254. The vertical strut 156 (FIG. 25B)of the working member 150 passes through the elongated slot 252 suchthat the upper beam 152 is slidably positioned in the elongated recess254 of the anvil 182. A proximal end of the anvil 182 defines a taperedcam surface 256 (FIG. 22A) which is positioned in engagement with adistal end of the upper beam 152 of the working member 150 when theanvil 182 is in the open position as shown in FIG. 22A. The lower beam154 is positioned to move along the bottom surface of the cartridgechannels 140 a, 140 b. As shown, the anvil 182 is biased to an openposition by a biasing member, e.g., one or more leaf springs 400 (FIG.3C). In embodiments, the leaf springs 400 have a U-shaped proximal end402 compressed between a proximal end of the cartridge body 184 and adistal face of the pivot member 157. A distal end of the leaf springs400 engages an undersurface of the anvil 182 to urge the anvil 182 tothe open position.

Referring briefly again to FIG. 3, the reload 100 includes a lockingmember 300 which is rotatably supported about a proximal end of theinner housing 116 of the proximal body portion 110. The locking member300 is movable from a first position in which the locking member 300blocks distal movement of the proximal drive member 118 to a secondposition in which the locking member 300 moves to a position to allowdistal movement of the proximal drive member 118. U.S. Pat. No.7,143,924 describes the locking member 300 and its method of operationin detail and is incorporated herein by reference in its entirety.

Referring again to FIGS. 3 and 21-25B, when the proximal drive member118 (FIG. 3) is in a retracted position, the drive member link 119 and,thus, the distal drive members 136 a, 136 b and the firing cam 138 a,138 b are also in a retracted position (FIG. 25B). In the retractedposition, the hook portion 119 a is engaged with the hook portions 144a, 146 a of the distal drive members 136 a, 136 b and the firing cams138 a, 138 b, respectively, and is positioned within the proximal end ofthe recesses 144 b, 146 b of the distal drive members 136 a, 136 b andthe firing cams 138 a, 138 b. In addition, the distal end of the upperbeam 152 of the working member 150 is positioned proximally of thetapered cam surface 256 (FIG. 22A) of the anvil 182 to allow the biasingmembers 400 to position or move the anvil 182 to the open positionspaced from the cartridge body 184 (FIG. 22A). In the retracted positionof the firing cams 138 a, 138 b, the cam surfaces 222 a, 222 b (FIG. 20)of each of the firing cams 138 a, 138 b is positioned proximally of thea respective leg 200 a, 200 b of the proximal-most staple 185 (FIG. 24A)such that a proximal end 259 (FIG. 18) of cam surface 222 b of eachfiring cam 138 a, 138 b is in abutment with a shoulder 260 (FIG. 6) of arespective leg 188 of the cartridge body 184. Referring to FIG. 26, whenthe proximal drive member 118 is advanced via operation of the actuatingdevice 12 (FIG. 1), the hook portion 119 a of the drive member link 119translates through the recesses 144 b, 146 b of the distal drive members136 a, 136 b and of the firing cams 138 a, 138 b. The recesses 146 b ofthe firing cams 138 a, 138 b extend distally of the recesses 144 b ofthe distal drive members 136 a, 136 b. When the hook member 119 a of thedrive member link 119 engages a wall 144 c, 146 c defining a distal endof the recesses 144 b and 146 b of the distal drive members 136 a, 136 band the firing cams 138 a, 138 b, respectively, distal movement of thedrive member link 119 will effect corresponding distal movement of thedistal drive members 136 c, 136 b and the firing cams 138 a, 138 b. Asdiscussed above, the wall 146 c defining the distal end of each of therecesses 146 b is positioned distally of the wall 144 c defining thedistal end of each of the recesses 144 b of the distal drive members 136a, 136 b. As such, distal movement of the drive member link 119 willcause movement of the distal drive members 136 a, 136 b before causingdistal movement of the firing cams 138 a, 138 b.

When the distal drive members 136 a, 136 b are advanced via the drivemember link 119, the working member 150 is advanced in relation to theanvil 182. As the working member 150 is advanced, the upper beam 152 ofthe working member 150 (FIG. 27) is moved over the tapered cam surface256 (FIG. 27) of the anvil 182 to pivot the anvil 182 to an approximatedposition (FIG. 26). In the approximated position, the distal end of thecam surfaces 222 a, 222 b of each of the firing cams 138 a, 138 b arepositioned immediately proximal of or in contact with the proximal legportion 202 a of the proximal-most staple of the plurality of staples185.

Referring to FIGS. 27-33, continued advancement of the proximal drivemember 118 (FIG. 25), will subsequently move the cam surfaces 222 a, 222b (only 222 b is shown in FIGS. 29-33) of each of the firing cams 138 a,138 b sequentially into contact with the staples 185. More particularly,when the firing cams 138 a, 138 b are advanced about legs 188 ofcartridge body 184, the cam surfaces 222 a, 222 b sequentially engagethe proximal leg portions 202 a of the staples 185 to rotate or pivotthe staples 185 about the proximal portion 204 b of the intermediateportion 201 within the notches 198. As the first curved cam surface 226of cam surfaces 222 a, 222 b moves under the proximal leg portion 202 aof each staple 185, each staple 185 is pivoted or rotated upwardly todirect the tapered tip 202 c of the staple 185 into a staple formingdepression 182 b of the anvil 182 to initiate deformation of the staple186 FIG. 28).

After the first curved cam surface 226 of the cam surfaces 222 a, 222 bmoves past the proximal leg portion 202 a of the staple 185, the plateau230 of the cam surfaces 222 a, 222 b moves under the proximal legportion 202 a of the staple 185. The height of the plateau 230 is lessthan the height of the rectangular cutouts 196 and the base 198 a of thenotches 198. As such, at this stage of advancement of the firing cams138 a, 138 b, the proximal-most staples 185 remain engaged with the legs188 of the cartridge body 184.

Upon continued advancement of the firing cams 138 a, 138 b, the secondcurved surface 228 of each of the cam surfaces 222 a, 222 b moves underthe staples 185. Engagement of the second curved surface 228 of the camsurfaces 222 a, 222 b fully deforms the staple 185 and disengages orseparates each staple 185 from the notches 198 of the legs 188 of thecartridge body 184. In that respect, the height at the proximal end ofthe second curved surface 228 of the cam surfaces 222 a, 222 b isgreater that the height of the cutouts 196 and the base 198 a of thenotches 198. As discussed above, the staple legs 200 a and 200 b of eachstaple 185 and the cam surfaces 222 a and 222 b of each of the firingcams 138 a and 138 b are staggered or offset axially. In embodiments,the degree of offset of the staple legs 200 a and 200 b is equal to thedegree of offset of the cam surfaces 222 a and 222 b such that the camsurfaces 222 a engage the legs 200 a of a staple 185 at the same timethat the cam surfaces 222 b engage the legs 200 b of the staple 185. Asshown in FIGS. 30 and 31, the legs 200 a, 200 b of the fully formedstaple 185 have substantially D-shape configurations and are axiallyoffset from each other.

Referring to FIGS. 3-3C and 33-37, the tool assembly 114 can bearticulated by movement of the cartridge channels 140 a, 140 b inopposite directions in relation to each other. As discussed above, thecartridge channels 140 a, 140 b extend from the proximal body portion110 through the elongated shaft portion 112 to the tool assembly 114. Adistal end of each of the cartridge channels 140 a, 140 b is connectedto the pivot member 157 by respective posts 172 (FIG. 3A) that extendthrough the proximal openings 210 a of the cartridge channels 140 a, 140b. The proximal ends of the cartridge channels 140 a, 140 b includecutouts 142 a, 142 b (FIG. 3B), respectively, that receive one side ofhook portions 120 a, 122 a of the articulation rods 120, 122,respectively, to connect the articulation rods 120, 122 to the cartridgechannels 140 a, 140 b. The first and second articulation links 120, 122are slidably supported between the housing halves 116 a, 116 b of theproximal body portion 110. The first articulation link 120 has a distalend connected to the cartridge channel 140 a and a proximal endconnected to an articulation assembly 350 (FIG. 1) of the actuatingdevice 12 (FIG. 1).

The articulation member 123 includes a C-shaped body 302 having spacedfingers 304, 306 and a central opening 308 (FIG. 34). The fingers 304,306 are received in cutouts 310 formed in the distal end of first andsecond articulation links 120 and 122. The central opening 308 receivesa housing post 312 (FIG. 35) formed on housing half 116 b of the centralbody portion 110 (FIG. 1) such that movement of the first articulationlink 120 in one direction as indicated by arrow “A” in FIG. 36 causesthe articulation member 123 to pivot about the housing post 312 to causemovement of the second articulation link 122 in a second direction asindicated by arrow “B” in FIG. 37.

In use, when the first articulation link 120 is moved by thearticulation assembly 350 in direction A, the cartridge channel 140 a,which is axially fixed to the first articulation link 120 by placementof hook portion 120 a in cutout 142 a (FIG. 3B), is also moved indirection A. Movement of the first articulation link 120 in direction Aeffects pivotal movement of the articulation member 123 which causesmovement of the second articulation link 122 in the direction of arrowB. Movement of the second articulation link 122 in direction of arrow Bcauses movement of cartridge channel 140 b in the direction of arrow B.

As discussed above, the distal ends of cartridge channels 140 a and 140b are connected to opposite sides of the pivot member 157 by posts 172.As the cartridge channels 140 a, 140 b are moved in opposite directions,the pivot member 157 is pivoted about the pivot pin 170 to pivot thetool assembly 114 in relation to shaft portion 112 such that thelongitudinal axis of the tool assembly 114 moves from a position alignedwith the longitudinal axis of the shaft portion 112 (FIG. 33) to aposition at an angle to the longitudinal axis of the shaft portion 112.It is noted that the cartridge channels 140 a, 140 b, the firing cams138 a, 138 b and the distal drive members 136 a, 136 b are all formed ofa resilient material such as spring steel to facilitate movement aboutthe axis of articulation, i.e., the axis of the pivot pin 170, to anarticulated position.

Persons skilled in the art will understand that the devices and methodsspecifically described herein and illustrated in the accompanyingdrawings are non-limiting exemplary embodiments. It is envisioned thatthe elements and features illustrated or described in connection withone exemplary embodiment may be combined with the elements and featuresof another without departing from the scope of the present disclosure.As well, one skilled in the art will appreciate further features andadvantages of the disclosure based on the above-described embodiments.Accordingly, the disclosure is not to be limited by what has beenparticularly shown and described, except as indicated by the appendedclaims.

What is claimed is:
 1. A surgical stapler comprising: a shaft portion; atool assembly supported on a distal end of the shaft portion, the toolassembly including an anvil and a cartridge assembly, the cartridgeassembly including a cartridge body having at least one leg defining aplurality of notches, and a plurality of staples, each of the stapleshaving an intermediate portion interconnecting first and second staplelegs wherein the intermediate portion of each of the staples has a firstend connected to the first leg and a second end connected to the secondleg, wherein the first and second ends of the intermediate portion areaxially offset from each other; and at least one firing cam including adistal end defining a cam member having first and second cam surfaces,the first and second cam surfaces being axially offset from each other,the cam member being movable within the tool assembly to move the firstand second cam surfaces into sequential engagement with the first andsecond staple legs, respectively, of each of the plurality of staples,wherein engagement between the cam member and the first and secondstaple legs of each of the plurality of staples effects rotationalmovement of each of the plurality of staples to fire each of theplurality of staples from the cartridge body.
 2. The surgical stapleraccording to claim 1, wherein each notch of the plurality of notches isconfigured to rotatably support one of the staples of the plurality ofstaples.
 3. The surgical stapler according to claim 1, wherein the atleast one leg of the cartridge body defines a plurality of cutouts, eachof the plurality of cutouts being spaced from adjacent notches of theplurality of notches and being configured to receive a first portion ofthe intermediate portion of one of the staples of the plurality ofstaples.
 4. The surgical stapler according to claim 1, wherein theintermediate portion of each of the staples is S-shaped and includes adistal U-shaped portion that is configured to be received in arespective one of the cutouts of the plurality of cutouts on the atleast one leg of the cartridge body.
 5. The surgical stapler accordingto claim 1, wherein each of the notches of the plurality of notches isconfigured to rotatably receive a proximal portion of the intermediateportion of a respective one of the staples of the plurality of staples.6. The surgical stapler according to claim 1, wherein the first andsecond staple legs of each of the staples of the plurality of stapleshas a curved configuration, wherein each of the first and second staplelegs defines a D-shape when formed against the anvil.
 7. The surgicalstapler according to claim 5, wherein each notch of the plurality ofnotches includes a cylindrical slot that is configured to receive theproximal portion of the intermediate portion of a respective one of thestaples of the plurality of staples in a snap-fit manner.
 8. Thesurgical stapler according to claim 1, wherein the at least one leg ofthe cartridge body includes two spaced legs, the plurality of notchesbeing spaced axially along each of the two spaced legs, and each of theplurality of notches rotatably supporting one of the staples of theplurality of staples.
 9. The surgical stapler according to claim 8,further including first and second cartridge channels, each of the firstand second cartridge channels having a distal end defining a U-shapedmember, each of the two spaced legs of the cartridge body being securedwithin a respective one of the U-shaped members.
 10. The surgicalstapler according to claim 9, wherein the at least one firing camincludes first and second firing cams, each of the cam members of thefirst and second firing cams having a U-shape and being positioned aboutone of the two spaced legs of the cartridge body and within the U-shapedmember of one of the first and second cartridge channels.
 11. Thesurgical stapler according to claim 10, further including a pivot memberpivotably secured to the distal end of the shaft portion and fixedlysecured to each of the first and second cartridge channels.
 12. Thesurgical stapler according to claim 11, further including a firstarticulation link having a distal end secured to a proximal end of thefirst cartridge channel and a second articulation link having a distalend secured to a proximal end of the second cartridge channel, the firstand second articulation links being axially movable to effect axialmovement of the first and second cartridge channels in relation to eachother to pivot the pivot member in relation to the shaft portion. 13.The surgical stapler according to claim 12, further including apivotable articulation member interconnecting the first articulationlink to the second articulation link such that movement of the firstarticulation link in one direction effects movement of the secondarticulation link in an opposite direction.
 14. The surgical stapleraccording to claim 1, wherein each of the first and second staple legsof each of the staples has a tapered tip.
 15. The surgical stapleraccording to claim 1, wherein each of the at least one leg of thecartridge body includes a plurality of dimples, each of the plurality ofdimples being positioned to engage one of the first and second legs ofone of the staples of the plurality of staples to stabilize the stapleon the cartridge body.
 16. A surgical staple comprising: a first curvedleg; a second curved leg; and an intermediate portion interconnectingthe first curved leg to the second curved leg; wherein the intermediateportion of the surgical staple has a first end connected to the firstcurved leg and a second end connected to the second curved leg, whereinthe first and second ends of the intermediate portion are axially offsetfrom each other.
 17. The surgical staple according to claim 16, whereinthe intermediate portion of the staple is S-shaped and includes a distalU-shaped portion and a proximal portion.
 18. The surgical stapleaccording to claim 16, wherein each of the first and second legsincludes a tapered tip.
 19. The surgical staple according to claim 16,wherein the first and second legs of the staple is configured to have aD-shape when formed against an anvil.